Doc. No.

PDC-EPD-F03

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (01/09/2019)

Issue No. (Date) 02 (01/09/2019)

PFMEA Number : 8941725283 FMEA -CAS-10-90 Key Contact / Phone Name / Works / Dept Team Member Deparment
Revision No. (Date) : 01(27/10/2021) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) : 05/05/2017 Mr. Suraj Rawat GM QA & QC
Part Number : 8941725291 Mr. Pradeep Garg GM Operations
Process Responsibility: Core Team
Part Name / Description : Flywheel ASM Mr. Samdar Singh Manager - Casting
Material Grade : FC 230 Key Date : 5.5.17 Mr. Ajit Kumar Pandey Manager - Lab

Current Process Controls Action Results

Process Potential Failure Potential Effect(s) of Potential Cause(s) / Mechanism(s) of Recommended Responsibility
Process Function / Requirements S C O D RPN
No. Mode Failure Failure Actions & Target Date
Prevention Detection Actions Taken S O D RPN

Wrong Chemical
Undesired
Composition resulting Incoming material out of
Pig Iron Chemical 6 4 Approved Supplier Sampling Test Every Lot 3 72
in Non Conforming specification
Properties
Properties

Low compactability of
Low/High pH molding sand. Incoming material out of
6 4 Approved Supplier Sampling Test Every Lot 3 72
Level High pH of molding specification
sand

Bentonite
Low compactability of Incoming material out of
Low Swelling 7 4 Approved Supplier Sampling Test Every Lot 3 84
molding sand specification

Incoming material out of

High Gelling Breakage of mold 7 4 Approved Supplier Sampling Test Every Lot 3 84
specification

Receiving Increase in the weight Incoming material out of

10 High Moisture 6 4 Approved Supplier Sampling Test Every Lot 3 72
Inspection of the sand. specification

Silica Less AFS of molding Incoming material out of

Low AFS No. 7 4 Approved Supplier Sampling Test Every Lot 3 84
Sand sand, Less GCS specification

Incoming material out of

High AFS no. Low Permeability 7 4 Approved Supplier Sampling Test Every Lot 3 84
specification

Ferro Less Recovery of Difficult to maintain Incoming material out of

6 4 Approved Supplier Supplier TC 3 72
Alloys alloy chemistry specification

Wrong Unwanted Incoming material out of

6 4 Approved Supplier Supplier TC 3 72
composition. microstructures specification
Inoculant
Oversize/Undersiz Incoming material out of
Less recovery 6 4 Approved Supplier Supplier TC 3 72
e specification

Wrong Chemical Incoming material out of

Copper Less Recovery 6 4 Approved Supplier Supplier TC 3 72
Composition specification

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 Doc. No. PDC-EPD-F03

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (01/09/2019)

Issue No. (Date) 02 (01/09/2019)

PFMEA Number : 8941725283 FMEA -CAS-10-90 Key Contact / Phone Name / Works / Dept Team Member Deparment
Revision No. (Date) : 01(27/10/2021) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) : 05/05/2017 Mr. Suraj Rawat GM QA & QC
Part Number : 8941725291 Mr. Pradeep Garg GM Operations
Process Responsibility: Core Team
Part Name / Description : Flywheel ASM Mr. Samdar Singh Manager - Casting
Material Grade : FC 230 Key Date : 5.5.17 Mr. Ajit Kumar Pandey Manager - Lab

Current Process Controls Action Results

Process Potential Failure Potential Effect(s) of Potential Cause(s) / Mechanism(s) of Recommended Responsibility
Process Function / Requirements S C O D RPN
No. Mode Failure Failure Actions & Target Date
Prevention Detection Actions Taken S O D RPN

Drop in Clay Addition, Extra Sand Preparation as per

Low Cut & Washes 6 2 5 60
Mulling Work Instruction
Sand Testing - One
Moisture ▼
Batch /90 Mins
Pin Holes& Rough Increase in Clay Addition, Sand Preparation as per
Higher 6 2 5 60
Surface Insufficient Mulling Work Instruction

Sand of Fine Grain Used,

Poor Finish, Burn in, Sand Preparation as per
Low 6 Improper mixing of sand & 2 5 60
Penetration Work Instruction
Additives Sand Testing - One Batch/
Permeability
90 Mins.
Sand of Coarse Grain Used,
Sand Sand Preparation as per
20 Higher Less Smooth Surface 6 Improper mixing of sand & 2 5 60
Preparation Work Instruction
Additives

Over Size Casting,

Poor Surface,
Scabbing, Broken Sand Preparation as per Sand Testing - One
Low 6 2 5 60
edges, Sand crushes, Work Instruction Batch/ 90 Mins.
Penetration, Burn on
Sand Strength etc. ▼ Improper Mould Preparation

Gas Entrapment, Sand Preparation as per Sand Testing - One

Higher 6 2 5 60
Scabbing, Leakages. Work Instruction Batch/ 90 Mins.

Heat Code, Visual Inspection of

Pattern Shop Incharge Pattern Shop Incharge
Cavity #, Heat #, Miss Casting , Rework 6 2 Patterns at the time of 7 84
Negligence Monitoring
Material Code Pattern Inspection
Pattern
20A
Inspection
Getting no Visual Inspection of
Pattern Pattern Shop Incharge Pattern Shop Incharge
proper of Casting Reject 7 2 Patterns at the time of 7 98
Condition Negligence Monitoring
pattern Pattern Inspection

Visual Inspection of
Casting Rework & Opeartor Monitoring/
Heat Codes Missing 4 Supervisor /Operator Negligence 2 Patterns/ Inspection at the 8 64
Punching Suprvisior Monitoring
Mould time of Issuing Pattern
30
Making
Mould Improper Sand Preparation & Mould Preparation as per
Low Extra Material 6 ▼ 2 5 Boxes/ Heat 5 60
Hardness Ramming WI

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 Doc. No. PDC-EPD-F03

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (01/09/2019)

Issue No. (Date) 02 (01/09/2019)

PFMEA Number : 8941725283 FMEA -CAS-10-90 Key Contact / Phone Name / Works / Dept Team Member Deparment
Revision No. (Date) : 01(27/10/2021) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) : 05/05/2017 Mr. Suraj Rawat GM QA & QC
Part Number : 8941725291 Mr. Pradeep Garg GM Operations
Process Responsibility: Core Team
Part Name / Description : Flywheel ASM Mr. Samdar Singh Manager - Casting
Material Grade : FC 230 Key Date : 5.5.17 Mr. Ajit Kumar Pandey Manager - Lab

Current Process Controls Action Results

Process Potential Failure Potential Effect(s) of Potential Cause(s) / Mechanism(s) of Recommended Responsibility
Process Function / Requirements S C O D RPN
No. Mode Failure Failure Actions & Target Date
Prevention Detection Actions Taken S O D RPN

Tool diameter less , Lack of

Vent not open
Mould Venting Blow hole in casting 6 ▼ awareness, Pin not pass to full 3 Work Instruction Visual Inspection 6 108
properly
Mould hole.
30
Making

Inspection of Patterns,
Broken Pattern, Improper Box
Appearance Broken Cavity Defective Casting 6 2 Proper Setting of Box & Sampling Inspection 6 72
Setting, Improper Ramming
Proper Ramming

Chemical Testing/ Charge Each Heat Chemical

High Loss in Properties 7 Improper Charge Mixing 2 4 56
Calculation Testing
Elements
Chemical Testing/ Charge Each Heat Chemical
Low Loss in Properties 7 Improper Charge Mixing 2 4 56
Calculation Testing

High pouring 100 % checking with

Checking with
High Tapping temperature/ Sand Operator's Negligence, Excess pyrometer & recording
7 2 pyrometer, In Process 5 70
temperature defects, shrinkage, power has been done by lab
Inspection
Tapping hot tesar, cracks person for every heat
Melting &
40 & 50 ▼
Pouring Temperature
100 % checking with
Low pouring Checking with
Low Tapping Operator's Negligence,Lower pyrometer & recording
temperature/Cold 7 2 pyrometer, In Process 5 70
temperature power has been done by lab
shut blow hole Inspection
person for every heat
100 % Monitoring &
High Loss in Properties 7 Operator's Negligence 2 Automatic Hooter & In Process Inspection 3 42
Pouring Process Sheet
Temperature & ▼
Time 100 % Monitoring &
Low Loss in Properties 7 Operator's Negligence 2 Automatic Hooter & In Process Inspection 3 42
Process Sheet

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 Doc. No. PDC-EPD-F03

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS Rev. No. (Date) 00 (01/09/2019)

Issue No. (Date) 02 (01/09/2019)

PFMEA Number : 8941725283 FMEA -CAS-10-90 Key Contact / Phone Name / Works / Dept Team Member Deparment
Revision No. (Date) : 01(27/10/2021) Mr. Vibhor V. Jain CEO
Mr. Vibhor V. Jain CEO
Date (Originated) : 05/05/2017 Mr. Suraj Rawat GM QA & QC
Part Number : 8941725291 Mr. Pradeep Garg GM Operations
Process Responsibility: Core Team
Part Name / Description : Flywheel ASM Mr. Samdar Singh Manager - Casting
Material Grade : FC 230 Key Date : 5.5.17 Mr. Ajit Kumar Pandey Manager - Lab

Current Process Controls Action Results

Process Potential Failure Potential Effect(s) of Potential Cause(s) / Mechanism(s) of Recommended Responsibility
Process Function / Requirements S C O D RPN
No. Mode Failure Failure Actions & Target Date
Prevention Detection Actions Taken S O D RPN

100 % Monitoring, Work

Monitoring of Knock out
High Loss in Properties 7 Operator's Negligence 2 Instruction Knock Out 3 42
time each heat
Chart

Knock Out Knock Out Time 60 ▼

100 % Monitoring, Work
Monitoring of Knock out
Low Loss in Properties 7 Operator's Negligence 2 Instruction Knock Out 3 42
time each heat
Chart

Visual Aid & Work

Excessive Pitting over Surface 7 More Blasting Time 2 Visual Inspection 5 70
Instruction
Shot
Blasting 70
Blasting
Visual Aid & Work
Poor Sand Stuck to parts 7 Less Blasting Time 2 Visual Inspection 5 70
Instruction

More Grinding Force, More

Excessive Shape Lost 4 2 Work Instruction Visual Inspection 4 32
Grinding Cut, Unskilled Operator
Grinding
Grinding 80
Process
Old / Broken Grinding Wheel,
Excessive Material
Poor 4 Less Grinding Force, Less 2 Work Instruction Visual Inspection 4 32
Remained
Grinding Cut, Unskilled Operator
Charge Calculation/
Microstructure
Not OK 8 ▼ Improper Composition 2 Dedicated Person for Micro Testing Each Heat 3 48
Test
innoculation
As Per Internal Sampling
Low Hardness 8 Improper Composition 2 Composition Chart 3 48
Plan
NON CONFORMING ▼
Lab Testing Hardness Test 90
PRODUCT As Per Internal Sampling
High Hardness 8 Improper Composition 2 Composition Chart 3 48
Plan

Tensile Each Heat Testing in a

Low Strength 8 ▼ Improper Composition 2 Composition Chart 3 48
Strength seprately cast test bar.

Remarks : Rev.01 Due to Reviewed

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